Apparatus and methods for additive-layer manufacturing of an article

Abstract

Apparatus is for additive layer manufacturing of an article from a material which can be rendered solid locally by application of a focused beam of laser radiation at a planar focal plane. The apparatus includes at least two laser beams, respective scanners for each laser beam for scanning the respective laser beams over a planar field, and a support movable stepwise to allow successive manufacturing layer cycles and for supporting material within the field. The entire planar field is common to each scanner and at least one scanner is tilted with respect to the planar field, and the at least one scanner is provided with a lens arranged to generate a focal plane tilted with respect to that scanner.

Description

FIELD OF THE INVENTION[0001]This invention relates to apparatus and methods for additive layer manufacturing using a focused beam of laser energy selectively directed to a planar focal plane adjacent a layer of powder or liquid to carry out a transformation where it strikes—such as a photo polymerisation, sintering or melting of powders thereby building a three dimensional part layer by layer as planar slices.BACKGROUND TO THE INVENTION[0002]The layer of powder or liquid is created by the stepwise sinking of the three dimensional part being built into a liquid vat or powder bed thereby presenting a new layer of untransformed material at the surface and retaining a planar focal plane for the laser at or near that surface. The application of material is distinct from the application of laser energy and the process is characterised in that the laser energy cannot address any layer lower or higher than the current layer in a manufacturing cycle. This is in distinction from methods that ...

AI Technical Summary

Benefits of technology

The patent is about using tilted scanners in combination with a lens to tilt the focal plane to improve the quality of 3D printing, while minimizing the impact on the build quality. This is beneficial because conventional 3D printing systems require large scanner and lens assemblies, which can lead to decreased accuracy of spot placement and size. By using a tilted scanner and lens, the depth of focus is made narrower, resulting in higher build quality.

Problems solved by technology

Firstly, conventional high build quality additive layer manufacture systems generally require relatively large scanner and lens assemblies in order to provide a small and precise spot size at the focal plane (which may typically require a spot size of about 70 microns).

Further, it is desirable to keep the distance between the lens and planar field to a minimum since increased distance (for example as might be necessary to enable two co-planar scanners to be positioned side-by-side over the planar field) generally leads to a decreased accuracy of spot placement and / or spot size.

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